Paintball and method of manufacture

ABSTRACT

The present invention relates to a paintball comprising a shell containing an inner filler composition. The shell comprises a mixture of gelatin and mineral oil; the inner filler composition comprises a mixture of starch, oil, an emulsifying agent and a spreading and surfacting agent. The shell further comprises a non-crystallizing polyhydric alcohol, glycerine, and water. The inner filler composition may further comprise a pigment. The non-crystallizing polyhydric alcohol may be sorbitol, the oil is Soya oil and the emulsifying agent is emulsifying wax. The spreading and surfacting agent may be Tween® 20 and the pigment may be TiO 2 .

This application is a continuation-in-the-part of application Ser. No. 11/640,944 filed on Dec. 19, 2006. The present invention relates to paintballs, and more particularly to a new and improved shell and paintball filler composition and method of manufacture.

For years, the paintball industry's standard ingredient for paintball filler has been polyethylene glycol as the base for all ingredients, such as shown in U.S. Pat. No. 5,393,054 to Rouffer issued Feb. 28, 1995. There are several grades of polyethylene glycol used for filler, but most common are polyethylene glycol 300 and 400.

Depending on formulae, the percentage of polyethylene glycol used in paintballs ranges from 75% to 95%. Additives that thicken the filler vary from manufacturer to manufacturer. Polyethylene glycol “PEG 3350”, starches, pigments, dyes and other ingredients have been added to enhance the thickness and marking ability of the filler. Glycerine, titanium and water are also used.

To produce a filler using these ingredients, it is necessary to first heat up the polyethylene glycol. After it reaches set temperature, polyethylene glycol PEG 3350 is added. When it dissolves to clear liquid, water, glycerine, blended dyes and titanium are added. Then the mixture must to be cooled down to become more viscous.

The primary disadvantage of these previously known paintballs is that they are costly due to use of polyethylene glycol. Attempts to use substitutes such as starches, oleic acid, and other cheaper ingredients have been unsuccessful due to the fragile balance between the paintball's shell and contents. Chemical incompatibilities caused the various fillers to dissolve the shell, rendering the paintball useless.

There is known U.S. Pat. No. 6,375,981 describing film-forming composition for capsules comprising a waxy starch, water, plasticizer and gum that may be used for production of soft gel for food, pharmaceutical and industrial applications. However, such composition may be not compatible with some fillers.

The present invention overcomes the above disadvantages; it relates to a new, less expensive paintball shell formula and a substantially cheaper filler formula.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT New Shell and Method of Manufacture

The main obstacle in producing a less-expensive filler is its instability with the conventional gelatin shell. Prior attempts to reduce the filler cost have yielded paintballs whose fill attacked the shell, resulting in complete paintball disintegration inside their packaging thus rendering themselves useless. Thus, it is of importance to the present invention that the gelatin shell be chemically stable with the filler.

The purpose of the present invention is to provide a more stable product where weather and temperature is concerned while also having benefits of provided cost stability by eliminating commodity driven PEG from the equation.

In the preferred embodiment, the paintball shell comprises:

-   -   Gelatin (39.29%)     -   Sorbitol (4.34%)     -   Glycerine (6.89%)     -   Drakeol 7™ (8.16%)     -   Water (41.32%)         Sorbitol plays the role of humectant or rubberizing agent, and         is related to a preferred non-crystallizing polyhydric alcohol.         Other non-crystalline forms of sorbitol are “Sorbo” and         “Sorbitol Special”, each of which is available from ICI         Americas. Other useful non-crystallizing polyhydric alcohols         include pentaerythritol, glycerol, propylene glycol, and         low-molecular-weight polyethylene glycol.

Drakeol 7™ pays the role of barrier agent and is related to a commercial brand of white mineral oil. Examples of suitable, commercially available mineral oils include Sonneborn™ and Carnation™ white oils from Witco, Isopar™ K and Isopar™ H from Exxon, and Peneteck™ white mineral oils from Penreco.

Gelatin plays the role of a gel-forming agent and water is a diluting agent.

The method of preparation of the preferred embodiment of the gelatin shell used in the encapsulation of the present paintball is as follows:

water, glycerine, sorbitol, and Drakeol 7™ are added into the reactor. The mixture is heated to 162° F. and the gelatin is added to the mixture. The mixture is heated further to 172° F. and mixed for 20 minutes. After appropriate mixing, the gelatin is chilled to 143.5° F. and ready for use.

Additional ingredients used in manufacturing of the shell according to the present invention, such as mineral oil, allow to balance shell composition with new filler of the present invention.

Mineral oil of the present invention (barrier agent) is used only inside the shell formulation. This mineral oil interacts with the gelatine of said shell to create a barrier against natural tendency of vegetable (Soya) oil (carrier agent) from the filler to penetrate inside the shell and to soften it, which is highly undesirable condition. Mineral oil of the present invention is provided to balance out the interaction of the vegetable oil from the filler with the shell, which is very important aspect of the present invention. In simple terms it helps to act as a barrier agent against the carrier agent (Soya oil) inside the paintball.

Method of Manufacture of Paintball Filler 1. One Phase Method:

The method of manufacture of paintball filler is the most important component of the present invention. Although a range of proportions and methods may be used (as described further), the preferred embodiments method comprises the following:

Starch (41.86%)

Soya Oil (52.23%)

Pigments (1.15%)

Tween® 20 (1.15%)

Emulsifying Wax (3.61%)

Starch acts as a thickening and binding agent, and various possible types of starch may be corn starch, potato starch, rice starch, wheat and tapioca. Starch is used to completely replace PEG, which is one of the most important features of the present invention.

Soya oil acts as a carrier agent and is the preferred oil; one may substitute corn oil, canola, peanut oil, olive oil, palm oil, linseed oil, or any combination thereof.

Tween® 20, also known generically as Polysorbate 20, is a surfactant and spreading agent. It also acts as an additional binding agent between starch and vegetable oil of the filler composition and provided to improve washability. The use of Tween® 20 is to bind the Soya oil with the first water particles it encounters. Being a part of the starch, water leeches from the shell and binds with Tween20. This helps not only in stabilizing the product, but also to improve washability.

Emulsifying wax acts as an emulsifying agent and additionally is used as a binding agent between two usually non-compatible materials, in this case, the starch and oil. It also keeps heavier particles of filler composition in suspense. Emulsifying wax of the present invention plays the role as a stabilizing agent and allows the final product to be washable, which is highly desirable feature of the present invention. Both ingredients Tween® 20 and wax bind the materials, but the emulsifying wax has the added property of keeping the heavier particles in suspension.

The content of starch and vegetable oil in the inner filler composition of the present invention is precisely balanced and formulated to achieve maximum performance, thickness and stability in extreme cold weather conditions, such as winter. It could perform when temperature outside is up to −10° Celsius, which is very advantageous feature of the present invention.

Such combination of the above ingredients is stable from leeching and degradation over time as all known fillers. Because of the above and because precise stability in formulation such paintball filler allows to withstand extreme cold temperature up to −10° Celsius.

Starch of the present filler play the roll of binding agent to bind the oil to help Polysorbate 20 in its function: helping to carry water to the oil and helping its dispersion when washing. Also starch has hydrophilic properties that allow it to leech and hold onto excess water in the shell further stabilizing the end product—the paintball.

The procedure for making the filler begins with half the Soya oil being introduced into the reactor. The starch is mixed in at high speed; once the mixture has been thoroughly mixed for 30 minutes, the remaining Soya oil is slowly introduced. Once the mixture is homogenous, Tween® 20 is slowly mixed in at high speed for 60 minutes to be integrated into the mixture. The mixture is then heated to 55° C. and the emulsifying wax is added. The mixture is again thoroughly mixed for 30 minutes at high speed to be integrated. Further, the mixture is chilled to 27° C., and pigments are introduced at high speed and mixed for 10 minutes. Once the mixture is smooth, it is ready for use.

While the above formula illustrates the preferred embodiment, it is understood that many variations are possible using starch and oil. In experimentation, the following limits have been discovered to produce acceptable results:

Lower: 30% Starch to 65% Oil

Upper: 50% Starch to 45% Oil

5% pigments, Tween® 20, dye and wax

Two Phase Method:

The above describes the preferred embodiment of the present invention. However, a two-phase variation is also possible:

Phase 1:

The ingredients for this phase are as follows:

-   -   TiO₂ (14.29%)     -   Tween® 20 (81.57%)     -   Dye (4.14%)         Tween® 20 and dye are thoroughly mixed at high speed and high         shear and filtered to remove any solid mass. When the mixture is         completely clear pigment agent, such as TiO₂ is then slowly         added in an emulsification procedure and mixed for an additional         10 minutes.

Phase 2:

The ingredients for phase 2 are as follows:

-   -   Starch (53.50%)     -   HPFU (a blend of oils) (37.50%)     -   TiO₂ (1.00%)     -   Phase 1 mixture (3.00%)     -   Emulsifying Wax (3.87%)         While ingredients of Phase 1 are mixing Phase 2 is in process:

HPFU is poured into the reactor and starch is slowly added while mixing at high speed with HPFU in the reactor for 60 minutes. TiO₂ is added slowly into the mixture and mixed for 10 minutes to facilitate complete blending of all ingredients. Further, all ingredients of Phase 1 are added at high speed and mixed for another 60 minutes Then mixture is heated to 65° C. and emulsifying wax is thoroughly blended into the pre-warmed mixture for 30 minutes at highest speed. Mixture is cooled down until the product is at room temperature and is ready for encapsulation.

Non-limiting examples of suitable oleaginous liquids used instead of Soya oil include mineral oils; natural oils such as castor oil, cottonseed oil, olive oil, almond oil, peanut oil, rapeseed oil, corn oil, sesame oil, safflower oil, hemp oil, linseed oil, tung oil, oiticica oil, jojoba oil, meadowfoam oil, and the like. Other suitable oleaginous liquids may include synthetic oils such as homo- and inter-polymers of C2-C12 olefins, carboxylic acid esters of both monoalcohols and polyols, polyethers, silicones, polyglycols, silicates, alkylated aromatics, carbonates, thiocarbonates, orthoformates, phosphates and phosphites, borates and halogenated hydrocarbons. Representative of such oils or homo- and interpolymers of C2-C12 monoolefinic hydrocarbons, alkylated benzenes (e.g., dodecyl benzenes, didodecyl benzenes, tetradecyl, benzenes, dinonyl benzenes, di-(2-ethylhexyl-)benzenes, wax-alkylated naphthalenes); and polyphenyls (e.g., biphenyls, terphenyls). Alkylene oxide polymers and interpolymers and derivatives thereof where the terminal hydroxyl groups have been modified by esterification, etherification, etc., constitute another class of synthetic oils.

Preferably, but not necessary paintballs of the present invention are manufactured by means of an encapsulating method which is known in the art.

There are some drawbacks to the above paintball, such as:

-   -   reduced surface area of the resulting paintball hit because the         filler of the present invention is thicker in consistency than         the prior art paintballs;     -   the use of the paintballs of the present invention is limited         mostly for cold or cool weather since the filler starts to         deteriorate when temperature is above 25° C.

Thus, it can be seen that the objects of the present invention have been satisfied by the structure presented hereinabove. While in accordance with the Patent Statutes, only the best mode and preferred embodiments of the present invention have been presented and described in detail, it is to be understood that the invention is not limited thereto or thereby. 

1. A paintball comprising: a shell containing an inner filler composition; wherein said shell comprises a mixture of a gelatine and a mineral oil; and wherein said inner filler composition comprises a mixture of a starch an oil an emulsifying agent and a spreading and surfacting agent wherein said mineral oil of said shell interacts with the gelatine to create a barrier preventing penetration into said shell of said oil contained in said inner filler composition and wherein said mineral oil further balances out interaction with said oil of said filler composition; wherein said starch is used as a thickening and binding agent and provided to completely replace a polyethylene glycol; wherein said emulsifying agent acts as a binding and stabilizing agent between said starch and said oil of said filler composition and is provided to keep heavier particles of said filler composition in suspension and to improve washability; wherein said spreading and surfacting agent acts as an additional binding agent between said starch and said oil of said filler composition and provided to improve washability; and wherein the proportions between said starch and said oil in said filler composition are precisely balanced and formulated to achieve maximum performance, thickness and stability of said filler composition in extreme cold weather conditions, ranging from 30% starch and 65% oil at the lower level to 50% starch and 45% oil in the upper level, and wherein said emulsifying agent and said spreading and surfacting agent contain the remaining 5% of the total mixture;
 2. Paintball according to claim 1, wherein said shell further comprises a non-crystallizing polyhydric alcohol, glycerine, water and a pigment.
 3. Paintball according to claim 2, wherein said non-crystallizing polyhydric alcohol is non-crystallizing sorbitol solution.
 4. Paintball according to claim 1, wherein said oil is Soya oil, said emulsifying agent is emulsifying wax and said spreading and surfacting agent is Polysorbate
 20. 5. Paintball according to claim 2, wherein said pigment is TiO₂.
 6. Paintball according to claim 2, wherein said shell contains 39.29% gelatine, 4.34% non-crystallizing polyhydric alcohol, 6.89% glycerine, 8.16% mineral oil and 41.33% water.
 7. A paintball comprising: a shell containing an inner filler composition; wherein said shell comprises a mixture of a gel-forming agent and a barrier agent; and wherein said inner filler composition comprises a mixture of a starch a carrier agent an emulsifying agent and a spreading and surfacting agent; wherein said barrier agent of said shell interacts with said gel-forming agent of said shell to create a barrier preventing penetration of the carrier agent of said filler composition into said shell and wherein said barrier agent is provided to balance out interaction with said carrier agent of said filler composition; wherein said starch is used as a thickening and binding agent and is provided to completely replace a polyethylene glycol; wherein the proportion of said starch and said carrier agent in said filler composition is precisely balanced and formulated to achieve maximum thickness, performance and stability to withstand extreme cold weather conditions; wherein said emulsifying agent facilitates binding between said starch and said carrier agent and provided to keep heavier particles of said filler composition in suspension thus improving stability of said filler composition; and wherein said spreading and surfacting agent further acts as an additional binding agent between said starch and said carrier agents.
 8. Paintball according to claim 7, wherein the proportion of said starch and the carrier agent in said inner filler composition is from 30% starch and 65% carrier agent at the lower level to 50% starch and 45% carrier agent in the upper level, and wherein said emulsifying agent and said spreading and surfacting agent contain the remaining 5% of the total mixture.
 9. Paintball according to claim 7, wherein said shell further comprises a humectant rubberizing agent, a diluting agent, glycerine and a pigment.
 10. Paintball according to claim 9, wherein said humectant rubberizing agent is a non-crystallizing polyhydric alcohol.
 11. Paintball according to claim 9, wherein said gel-forming agent is gelatine, said diluting agent is water, said carrier agent is oil, said emulsifying agent is emulsifying wax and said spreading and surfacting agent is Polysorbate
 20. 12. Paintball according to claim 10, wherein said non-crystallizing polyhydric alcohol is non-crystallizing sorbitol solution.
 13. Paintball according to claim 11, wherein said oil is Soya oil.
 14. Paintball according to claim 9, wherein said pigment agent is TiO₂.
 15. Paintball according to claim 11, wherein said shell contains 39.29% gelatine, 4.34% non-crystallizing polyhydric alcohol, 6.89% glycerine, 8.16% oil and 41.33% water. 